Preparative process for alkaline earth metal, aluminum-containing spinels and their use for reducing sulfur oxide content in gases

ABSTRACT

An improved process for the production of alkaline earth, aluminum-containing spinel compositions, preferably magnesium, aluminum-containing spinel compositions and preferably further comprising at least one additional metal component, comprises combining at least one alkaline earth metal component; at least one solid organic material acting to alter at least one property of the spinel composition and being capable of being at least partially combusted during the calcination step described hereinafter, and at least one aluminum component at selected pH conditions to form a precipitate and calcining the precipitate to form a spinel composition. The product spinel composition, prepared in the presence of a solid organic material and preferably with included additional metal components, is particularly suited for use to reduce the amount of sulfur oxides emitted from a catalyst regeneration zone, e.g., a catalytic cracking unit regeneration zone.

BACKGROUND OF THE INVENTION

This invention relates to the improved preparation of alkaline earthmetal, aluminum-containing spinel compositions, particularly for use inthe combusting of solid, sulfur-containing material in a manner toeffect a reduction in the emission of sulfur oxides to the atmosphere.In one specific embodiment, the invention involves the catalyticcracking of sulfur-containing hydrocarbon feedstocks in a manner toeffect a reduction in the amount of sulfur oxides emitted from theregeneration zone of a hydrocarbon catalytic cracking unit.

Typically, catalytic cracking of hydrocarbons takes place in a reactionzone at hydrocarbon cracking conditions to produce at least onehydrocarbon product and to cause carbonaceous material (coke) to bedeposited on the catalyst. It has been reported that approximately 50%of the feed sulfur is converted to H₂ S in the fluid bed catalyticcracking (FCC) reactor, 40% remains in the liquid products and about 4to 10% is deposited on the catalyst. These amounts vary with the type offeed, rate of hydrocarbon recycle, steam stripping rate, the type ofcatalyst, reactor temperature, etc.

Sulfur-containing coke deposits tend to deactivate cracking catalyst.Cracking catalyst is advantageously continuously regenerated, bycombustion with oxygen-containing gas in a regeneration zone, to lowcoke levels, typically below about 0.4% by weight, to performsatisfactorily when it is recycled to the reactor. In the regenerationzone, at least a portion of sulfur, along with carbon and hydrogen,which is deposited on the catalyst, is oxidized and leaves in the formof sulfur oxides (SO₂ and SO₃, hereinafter referred to as "SOx") alongwith substantial amounts of CO, CO₂ and H₂ O.

Considerable recent research effort has been directed to the reductionof sulfur oxide emissions from the regeneration zones of hydrocarboncatalytic cracking units. One technique involved circulating one or moremetal oxides capable of associating with oxides of sulfur with thecracking catalyst inventory in the regeneration zone. When the particlescontaining associated oxides of sulfur are circulated to the reducingatmosphere of the cracking zone, the associated sulfur compounds arereleased as gaseous sulfur-bearing material such as hydrogen sulfidewhich is discharged with the products from the cracking zone and are ina form which can be readily handled in a typical facility, e.g.,petroleum refinery. The metal reactant is regenerated to an active form,and is capable of further associating with the sulfur oxides when cycledto the regeneration zone.

Incorporation of Group II metal oxides on particles of cracking catalystin such a process has been proposed (U.S. Pat. No. 3,835,031 toBertolacini). In a related process described in U.S. Pat. No. 4,071,436to Blanton, et al., discrete fluidizable alumina-containing particlesare circulated through the cracking and regenerator zones along withphysically separate particles of the active zeolitic cracking catalyst.The alumina particles pick up oxides of sulfur in the regenerator,forming at least one solid compound, including both sulfur and aluminumatoms. The sulfur atoms are released as volatiles, including hydrogensulfide, in the cracking unit. U.S. Pat. No. 4,071,436 further disclosesthat 0.1 to 10 weight percent MgO and/or 0.1 to 5 weight percent Cr₂ O₃are preferably present in the alumina-containing particles. Chromium isused to promote coke burnoff.

A metallic component, either incorporated into catalyst particles orpresent on any of a variety of "inert" supports, is exposed alternatelyto the oxidizing atmosphere of the regeneration zone of an fluid bedcatalytic cracking unit (FCCU) and the reducing atmosphere of thecracking zone to reduce sulfur oxide emissions from regenerator gases inaccordance with the teachings of U.S. Pat. Nos. 4,153,534 and 4,153,535to Vasalos and Vasalos, et al., respectively. In Vasalos, et al., ametallic oxidation promoter such as platinum is also present when carbonmonoxide emissions are to be reduced. These patents disclose nineteendifferent metallic components, including materials as diverse asalkaline earths, sodium, heavy metals and rare earth, as being suitablereactants for reducing emissions of oxides of sulfur. The metallicreactants that are especially preferred are sodium, mangnesium,manganese and copper. When used as the carrier for the metallicreactant, the supports that are used preferably have a surface area atleast 50 square meters per gram. Examples of allegedly "inert" supportsare silica, alumina and silica-alumina. The Vasalos and Vasalos, et al.,patents further disclose that when certain metallic reactants(exemplified by oxides or iron, manganese or cerium) are employed tocapture oxides of sulfur, such metallic components can be in the form ofa finely divided fluidizable powder.

Similarly, a vast number of sorbents have been proposed fordesulfurization of non-FCCU flue gases in zones outside the unit inwhich SOx is generated. In some such non-FCCU applications, the sorbentsare regenerated in environments appreciably richer in hydrogen than thecracking zone of an FCC unit. Cerium oxide is one of fifteen adsorbentsdisclosed for flue gas desulfurization in a publication of Lowell, etal., "SELECTION OF METAL OXIDES FOR REMOVING SOx FROM FLUE GAS," Ind.Eng. Chemical Process Design Development, Vol. 10, Nov. 3, 1971. In U.S.Pat. No. 4,001,375 to Longo, cerium on an alumina support is used toabsorb SO₂ from non-FCCU flue gas streams or automobile exhaust attemperatures of 572° to 1472° F., preferably 932° to 1100° F. Duringregeneration the desorbed species is initially SO₂ and H₂ S along withexcess reducing gases which can be used as feedstock for a Claus unit.The Longo patent is not concerned with reducing emissions from an FCCunit and the reducing emissions from an FCC unit and the reducingatmosphere employed in practice of this process differs significantlyfrom the hydrocarbon-rich atmosphere in a catalytic cracker. Thus, ahydrocarbon cracking reaction zone is preferably operated in thesubstantial absence of added hydrogen while the presence of sweepingamounts of hydrogen gas is essential to the regeneration step inpractice of the process of Longo.

D. W. DeBerry, et al., "RATES OF REACTION OF SO₂ WITH METAL OXIDES,"Canadian Journal of Chemical Engineering, 49, 781 (1971), reports thatcerium oxide was found to form sulfates more rapidly than most of theother oxides tested. The temperatures used, however, were below 900° F.and thus below those preferred for use in catalyst regenerators in FCCunits.

Many commercial zeolitic FCC catalyst contain up to 4% rare earth oxide,the rare earth being used to stabilize the zeolite and provide increasedactivity. See, for example, U.S. Pat. No. 3,930,987 to Grand. The rareearths are most often used as mixtures of La₂ O₃, Pr₆ O₁₁, Nd₂ O₃ andothers. Some catalyst is produced by using a lanthanum-rich mixture ofrare earth. It has been found that the mere presence of rare earth in azeolitic cracking catalyst will not necessarily reduce SOx emissions toan appreciable extent.

In accordance with the teachings of U.S. Pat. No. 3,923,092 to Gladrow,certain zeolitic catalyst compositions capable of being regenerated at arate appreciably faster than prior art rare earth exchanged zeoliticcatalyst compositions are produced by treating a previously rare earthexchanged zeolitic catalyst composition with a dilute solutioncontaining cerium cations (or a mixture of rare earths rich in cerium).The final catalyst contain 0.5 to 4% cerium cations which are introducedto previously rare earth exchanged zeolitic catalyst particles prior tofinal filtering, rinsing and calcining. Cerium is described as an"oxidation promoter". There is not recognition or appreciation in thepatent of the effect of the cerium impregnation of SOx stack emissions.Such impregnation of rare earth exchanged zeolitic catalyst particles isnot always effective in producing modified catalysts having significantability to bind oxides of sulfur in a FCC regenerator and release themin a FCC cracking reaction zone.

Thus, considerable amount of study and research effort has been directedto reducing oxide of sulfur emissions from various gaseous streams,including those from the stacks of the regenerators of FCC units.However, the results leave much to be desired. Many metallic compoundshave been proposed as materials to pick up oxides of sulfur in FCCunits (and other desulfurization applications) and a variety ofsupports, including particles of cracking catalysts and "inerts", havebeen suggested as carriers for active metallic reactants. Many of theproposed metallic reactants lose effectiveness when subjected torepeated cycling. Thus, when Group II metal oxides are impregnated onFCC catalysts or various supports, the activity of the Group II metalsis rapidly reduced under the influence of the cyclic conditions.Discrete alumina particles, when combined with silica-containingcatalyst particles and subjected to steam at elevated temperatures,e.g., those present in FCC unit regenerators, are of limitedeffectiveness in reducing SOx emissions. Incorporation of sufficientchromium on an alumina support to improve SOx sorption results inundesirably increased coke and gas production.

Commonly assigned U.S. patent applications, namely, U.S. applicationSer. No. 494,602, filed May 16, 1983, and U.S. application Ser. No.494,753, filed May 16, 1983, U.S. Pat. No. 4,469,589, relate to improvedmaterials for reducing SOx emissions, incorporating, respectively,spinel compositions, preferably alkaline earth metal-containing spinels,and spinel compositions including at least one additional metalcomponent. The specification of each of these patent applications isincorporated herein by reference.

Various methods have been described for the preparation of alkalineearth aluminate spinels, and particularly of magnesium aluminatespinels. According to the method disclosed in U.S. Pat. No. 2,992,191,the spinel can be formed by reacting, in an aqueous medium, awater-soluble magnesium inorganic salt and a water-soluble aluminum saltin which the aluminum is present in the anion. This patent does notteach controlling pH during the time the two salts are combined.

Another process for producing magnesium aluminate spinel is set forth inU.S. Pat. No. 3,791,992. This process includes adding a highly basicsolution of an alkali metal aluminate to a solution of a soluble salt ofmagnesium with no control of pH during the addition, separating andwashing the resulting precipitate; exchanging the washed precipitatewith a solution of an ammonium compound to decrease the alkali metalcontent; followed by washing, drying, forming and calcination steps.

Further commonly assigned U.S. patent applications, namely, U.S.application Ser. No. 445,304, filed Nov. 29, 1982, U.S. application Ser.No. 445,305, filed Nov. 29, 1982, U.S. application Ser. No. 445,306,filed Nov. 29, 1982, and U.S. application Ser. No. 445,130, filed Nov.29, 1982, U.S. Pat. No. 4,471,070 relate to novel process steps for theimproved production of alkaline earth metal and aluminum-containingspinel compositions. The specification of each of these patentapplications is incorporated herein by reference.

U.S. Pat. No. 4,428,827 teaches producing a sulfur acceptor solidcontaining magnesium, sodium and aluminum using a precipitating agent tocause the formation of highly insoluble magnesium and aluminum using aprecipitate to cause the formation of a highly insoluble magnesium andaluminum salts which will remain stable in an alkaline solution.

Attention has been given to improved zeolite catalyst compositions ofspecific pore diameters prepared under conditions where a portion of thealkali metal ion component is replaced by a nitrogen base such asammonium ion or a basic organic nitrogen compound. Rub, et al., U.S.Pat. No. 4,021,447 describes the preparation of ZSM-4 by synthesis inthe presence of pyrrolidine or choline salts, rather thantetramethylammonium hydroxide or halide, to yield the same crystalstructure. Improved stability is also claimed. Similarly, Plant, et al.,U.S. Pat. No. 4,021,502 employs ammonium or alkyl ammonium salts inzeolite formation. Argauer, et al., U.S. Reissue Pat. No. 29,857similarly prepares ZSM-5 catalysts. Rollmann, U.S. Pat. No. 4,148,713employs tetrapropyl ammonium cations and Rankel, et al., U.S. Pat. No.4,388,285 prepares ZSM-5 catalyst with the aid of complexes such as ametal phthalocyanin, iron cyclopentadienyl, and the like.

Daniels, et al., in "CATIONIC POLYMERS AS TEMPLATES IN ZEOLITECRYSTALLIZATION", J. American Chemical Society, Vol. 100, Pages3097-3100, May 15, 1978, describe their experience with certain organicpolymers in forcing the crystallization of large-pore mordenite underconditions which would otherwise have led to small-pore zeolites. Only asmall number of such polyelectrolytes were found to be effective. Haas,et al., in "PREPARATION OF METAL OXIDE GEL SPHERES WITH HEXAMETHYLENETETRAMINE AS AN AMMONIA DONOR", Ind. Eng. Chem. Product ResearchDevelopment, Vol. 22, No. 3, Pages 481-486, 1983, describes the use ofsuch nitrogen complexes as a source for the slow release of ammonia inthe precipitation of hydrous oxide gels which yield oxide spheres havinghigh surface area and other desirable properties.

There remains a need for improved spinel catalyst components, exhibitinggood SOx removal properties, and for improved processing in theirmanufacture.

SUMMARY OF THE INVENTION

This invention relates to a novel process for the improved production ofalkaline earth metal and aluminum-containing spinel compositions. Suchspinels find particular use in diminishing the emissions of sulfuroxides from combustion zones, and more particularly in conjunction withcatalytic compositions employed in hydrocarbon cracking processes.

The process of this invention further provides for the association ofone or more additional components with the alkaline earth metal,aluminum-containing spinel composition.

The improved process of this invention particularly provides for theadmixture of components to form a precipitate whereby controlled pHconditions are maintained. This improved process further provides forcalcination of the resulting precipitate conducted at a temperaturecapable of effective spinel formation, preferably such that a suitablehigh surface area is achieved. A novel component of this improvedproduction process for spinels is at least one of certain solid organicmaterials which is capable of being at least partially, preferablysubstantially totally, combusted during calcination of the precipitate.

Other objects and advantages of this invention will be apparent from thefollowing detailed description.

DESCRIPTION OF THE INVENTION

This invention broadly relates a novel process for the production ofalkaline earth metal, aluminum-containing spinel compositionscomprising:

(a) combining (i) an acidic aqueous medium, preferably an aqueoussolution, containing at least one alkaline earth metal component; (ii)at least one solid organic material capable of being at least partiallycombusted during the calcining step described below; and (iii) a basicaqueous medium, preferably an aqueous solution, containing at least onealuminum component in which the aluminum is present as an anion to forma combined mass including a liquid phase and an alkaline earth metal,aluminum-containing precipitate, provided that the pH of said combinedmass during said combining is maintained at about 8.0 or higher,preferably in the range of about 8.0 to about 10.5, more preferablyabout 8.5 to about 10 and still more preferably about 9.0 to about 9.5;and

(b) calcining said precipitate to form said alkaline earth metal,aluminum-containing spinel composition.

The solid organic materials useful in the present invention may be firstcombined with the aqueous medium containing the alkaline earth metalcomponent or with the aqueous medium containing the aluminum componentor both. Alternately, this solid organic material may be combinedseparately from either the alkaline earth metal component or thealuminum component, e.g., in the form of an aqueous mixture (suspension)of such solid organic material. In any event, such solid organicmaterial(s) is (are) present during at least a part of the time,preferably a major part of the time and more preferably substantiallyall of the time, during which the above-noted precipitation takes place.

The presently prepared spinel compositions may be used, for example, inthe form of particles of any suitable shape and size. Such particles maybe formed by conventional techniques, such as spray drying, pilling,tabletting, extrusion, bead formation (e.g., conventional oil dropmethod) and like. When spinel-containing particles are to be used in afluid catalytic cracking unit, it is preferred that a major amount byweight of the spinel-containing particles have diameters in the range ofabout 10 microns to about 250 microns, more preferably about 20 micronsto about 125 microns.

This invention further relates to the production of an alkaline earthmetal and aluminum-containing spinel composition which also includes atleast one additional metal component in an amount effective to promotethe oxidation of SO₂ to SO₃ at SO₂ oxidation conditions. The additionalmetal component may be added to the alkaline earth metal,aluminum-containing precipitate or spinel composition using techniques,such as impregnation, which are conventional and well known in the art.

The spinel structure is based on a cubic close-packed array of oxideions. Typically, the crystallo-graphic unit cell of the spinel structurecontains 32 oxygen atoms. With regard to magnesium aluminate spinel,there often are eight Mg atoms and sixteen Al atoms to place in a unitcell (8MgAl₂ O₄). Other alkaline earth metal ions, such as calcium,strontium, barium and mixtures thereof, may replace all or a part of themagnesium ions. Other trivalent metal ions, such as iron, manganese,chromium, gallium, boron, cobalt and mixtures thereof, may replace aportion of the aluminum ions.

The presently useful alkaline earth metal and aluminum containingspinels include a first metal (alkaline earth metal) and aluminum as thesecond metal having a valence higher than the valence of the firstmetal. The atomic ratio of the first metal to the second metal in anygiven alkaline earth metal and aluminum containing spinel need not beconsistent with the classical stoichiometric formula for such spinel. Inone embodiment, the atomic ratio of the alkaline earth metal to aluminumin the spinels of the present invention is preferably at least about0.17 and more preferably at least about 0.25. It is preferred that theatomic ratio of alkaline earth metal to aluminum in the spinel be in therange of about 0.17 to about 2.5, more preferably about 0.25 to about2.0, and still more preferably about 0.5 to about 1.5.

The preferred spinel composition of the present invention is magnesiumand aluminum-containing spinel composition.

The alkaline earth metal components useful in the present inventioninclude those which are suitable to provide the above-noted spinelcompositions. It is preferred that the alkaline earth metal component orcomponents employed be substantially soluble in the acidic aqueousmedium used. Examples of suitable alkaline earth metal component includenitrates, sulfates, formates, acetates, acetylacetonates, phosphates,halides, carbonates, sulfonates, oxalates, and the like. The alkalineearth metals include beryllium, magnesium, calcium, strontium, andbarium. The preferred alkaline earth metal components for use in thepresent invention are those comprising magnesium.

As noted above, the aluminum components present in the basic solutionuseful in the present invention are those in which the aluminum ispresent as an anion. Preferably, the aluminum salt is present as analuminate salt, more preferably as an alkali metal aluminate.

Any suitable acid or combination of acids may be employed in thepresently useful acidic aqueous solutions. Examples of such acidsinclude nitric acid, sulfuric acid, hydrochloric acid, acetic acid andmixtures thereof, with nitric acid, sulfuric acid and mixtures thereofbeing preferred. Any suitable basic material or combination of suchmaterials may be employed in the presently useful basic aqueoussolutions. Examples of such basic material include alkali metalhydroxides, ammonium hydroxide and mixtures thereof, with alkali metalhydroxides, and in particular sodium hydroxide, being preferred for use.The relative amounts of acids and basic materials employed are suitableto provide the desired alkaline earth metal, aluminum-containingprecipitate and the pH control as noted above.

One of the novel components of the process of this invention comprisesat least one of certain solid organic materials capable of being atleast partially combusted at the conditions at which the presentlyuseful precipitate is calcined and which preferably act to alter atleast one property of the spinel composition. These materials arepreferably maintained in the solid state during the time at least aportion, more preferably a major portion and still more preferablysubstantially all of the precipitation takes place.

Such solid organic materials may vary greatly in their structures andcompositions. These materials are preferably selected from the groupconsisting of substantially hydrocarbon materials, substantiallycarbohydrate materials, substantially carbonaceous materials andmixtures thereof. These substantially hydrocarbon and substantiallycarbohydrate materials typically include about 8 to about 1000 or morecarbon atoms per molecule. Examples of the presently useful solidorganic materials include cotton fibers, wooden flours, cellulose,alkali cellulose and modified derivatives of cellulose, graphite, paperpulp wastes, coals, lignins, and their derivatives, fatty acids, fattyesters, fatty ethers, fats and oils, starch, starch derivatives, naturalrubbers, stereo-specific and regio-specific organic polymers,polyolefins, polyamides, polyamines, polyesters, polyaromatics,synthetic rubbers, polystyrenes, polyvinyl acetates, polyolefin esters,epoxy resins, polyester acrylates, phenolic resins, acrylic polymers,grafted polymers and copolymers, other binary and ternary elastomersfrom olefins, diolefins and nitriles.

More preferably, the presently useful solid organic materials areselected from the group consisting of vegetable oils, fatty acids, fattyesters, fatty ethers, natural gums, starch, starch derivatives, lignin,lignin derivatives, cellulose, cellulose derivatives (such as celluloseesters and ethers), stereo-specific organic polymers, regio-specificorganic polymers and mixtures thereof. One particularly preferred solidorganic material is selected from the group consisting of hydrogenatedvegetable oils and mixtures thereof, for example hydrogenated coconutoil and/or similar triglycerides.

The terms "substantially hydrocarbon materials", "substantiallycarbohydrate materials" and "substantially carbonaceous materials" aremeant to include hydrocarbon materials, and carbohydrate materials andcarbonaceous materials, respectively, as well as those materials whichinclude minor, non-interferring amounts of other elements, such asnitrogen, phosphorus, sulfur, halogen and the like which do notsubstantially interfere with the hydrocarbon, carbohydrate orcarbonaceous, as the case may be, nature of the material.

The presently useful organic compounds preferably act to facilitateachieving an improved spinel formation. These organic compounds havebeen found to affect one or more of nucleation, gelation, and aging ofthe precipitate formed in the process of the present invention.

Preferably, the present organic compounds function in the presentinvention substantially without forming chemical compounds with thealkaline earth metal- and aluminum-containing entities present duringthe precipitation or in the combined mass.

The slurry comprising the precipitate and the liquid phase, may beallowed to age (in the presence of the organic compound or compounds)for about 4 hours to as long as 120 days, preferably for about 4 toabout 24 hours. The slurry may be aged at temperatures ranging fromambient to about 100° C., preferably at or about ambient temperature.

The weight ratio of the solid organic material (template) to elementalalkaline earth metal, e.g., magnesium, in the combined mass ispreferably in the range of about 0.1 to about 35, and more preferablywithin the range of about 0.3 to about 20.

Spinel compositions resulting from the present invention have improvedproperties relative to spinels produced without the present organicmaterial inclusion and pH control. For example, the presently preferredspinel compositions have improved capabilities, e.g., stability, ofreducing sulfur oxide emissions from hydrocarbon catalytic crackingoperations.

In certain embodiments of this invention, particulate materialcomprising the alkaline earth metal and aluminum-containing spinelcomposition also contains at least one additional metal component. Theseadditional metal components are defined as being capable of promotingthe oxidation of sulfur dioxide to sulfur trioxide at combustionconditions, e.g., the conditions present in a hydrocarbon catalyticcracking unit regenerator. Increased carbon monoxide oxidation may alsobe obtained by including the additional metal components. Suchadditional metal components are selected from the group consisting ofGroup IB, IIB, IVB, VIA, VIB, VIIA and VIII of the Periodic Table, therare earth metals, vanadium, tin, antimony, and mixtures thereof, andmay be incorporated into the presently useful spinel compositions by oneor more embodiments of the process of this invention. The preferredadditional metal component for use is selected from the group consistingof bismuth, rare earth metals, chromium, copper, iron, manganese,vanadium, tin, the platinum group metals, thorium, and mixtures thereof.A particularly preferred additional metal component is cerium.

The amount of the additional metal component or components present inthe final product is often small compared to the quantity of the spinel.Preferably, the final product comprises a minor amount by weight of atleast one additional metal component, preferably up to about 25% byweight (calculated as elemental metal). Of course, the amount ofadditional metal used will depend, for example, on the degree of sulfurdioxide oxidation desired and the effectiveness of the additional metalcomponent to promote such oxidation. When, as is more preferred, theadditional metal component is rare earth metal component (still morepreferably cerium component), the preferred amount of this additionalmetal component is within the range of about 1 to about 25 wt. %, morepreferably about 2 to about 15 wt. %, still more preferably about 3 toabout 12 wt. % (calculated as the rare earth metal) of the total finalproduct.

The additional metal component may exist in the final product at leastin part as a compound such as an oxide, sulfide, halide and the like, orin the elemental state.

The precipitate, which is preferably dried, is calcined to yield thealkaline earth metal, aluminum-containing spinel composition. Drying andcalcination may take place simultaneously. However, it is preferred thatthe drying take place at a temperature below that at which water ofhydration is removed from the spinel precursor, i.e., precipitate. Thus,this drying may occur in flowing air temperatures below about 500° F.,preferably in the range of about 150° F. to about 450° F., morepreferably about 230° F. to about 450° F. Alternatively, the precipitatecan be spray dried.

The drying of the precipitate can be accomplished in various manners,for example, by spray drying, drum drying, flash drying, tunnel dryingand the like. The drying temperature or temperatures is selected toremove at least a portion of the liquid phase. Drying times are notcritical to the present invention and may be selected over a relativelywide range sufficient to provide the desired dried product. Drying timesin the range of about 0.2 hours to about 24 hours or more may beadvantageously employed.

Spray drying equipment which is conventionally used to produce catalystparticles suitable for use in fluidized bed reactors may be utilized inthe practice of the present invention. For example, this equipment mayinvolve at least one restriction or high pressure nozzle having adiameter in the range from about 0.01 in. to about 0.2 in., preferablyfrom about 0.013 in. to about 0.15 in. The pressure upstream of thishigh pressure nozzle may range from about 400 psig. to about 10,000psig., preferably from about 400 psig. to about 7,000 psig. The materialto be dried is sent through the nozzle system into a space or chamber.The pressure in the space or chamber downstream from the nozzle systemis lower than that immediately upstream of the nozzle and is typicallyin the range from about 0 psig. to about 100 psig., preferably fromabout 0 psig. to about 20 psig. Once through the nozzle, the material tobe dried is contacted for a relatively short time, e.g., from about 0.1seconds to about 20 seconds with a gas stream which is at a temperatureof from about 200° F. to about 1500° F., preferably from about 200° F.to about 750° F. The gas stream which may be, for example, air or theflue gases from an inline burner (used to provide a gas stream havingthe proper temperature) or a substantially oxygen-free gas, may flowco-current, counter-current or a combination of the two relative to thedirection of flow of the material to be dried. The spray dryingconditions, such as temperatures, pressures and the like, may beadjusted because, for example, of varying the composition of thematerial to be dried to obtain optimum results. However, thisoptimization may be achieved through routine experimentation.

An alternative to the high pressure nozzle described above is the"two-fluid" nozzle in which the material to be dried is dispersed by astream of gas, typically air. The two fluid nozzle has the advantage oflow operating pressure, e.g., from about 0 psig. to about 60 psig. forthe material to be dried and from about 10 psig. to about 100 psig. forthe dispersing gas. The dispersing gas may also function as at least aportion of the drying gas stream. The various operating parameters notedabove may be varied in order to achieve the correct or desired boundparticle size.

In order to minimize contact between the chamber walls and wet material,the chamber downstream from the nozzle system is large in size, e.g.,from about 4 to about 30 feet in diameter and from about 7 to about 30feet long, often with an additional conical shaped portion forconvenient withdrawal of the dried material. The spray drying apparatusmay also include separation means, e.g., cyclone separators, in theoutlet gas line to recover at least a portion of the dried materialentrained in this stream.

Suitable calcination temperatures for the precipitate are in the rangeof about 1000° F. to about 1800° F. However, it has been found thatimproved spinel formation occurs when the calcination temperature ismaintained within the range of about 1050° F. to about 1600° F., morepreferably about 1100° F. to about 1400° F. and still more preferablyabout 1150° F. to about 1350° F. Calcination of the precipitate may takeplace in a period of time in the range of about 0.5 hours to about 24hours or more, preferably in a period of time in the range of about 1hour to about 10 hours. The calcination of the precipitate may occur atany suitable conditions, e.g., inert, reducing or oxidizing conditions,although oxidizing conditions are preferred.

In one embodiment of the process of this invention it has beendiscovered that improved spinel compositions are afforded byimpregnation procedures. Such preparative procedures preferably comprisethe impregnation of at least one or certain additional metal components,noted previously, on the precipitate or the spinel composition, followedby drying and, preferably, calcination.

In one preferred embodiment of this invention, calcination of the spinelcomposition after contacting with the additional metal component orcomponents is effected at oxidizing conditions, e.g., in a stream offlowing air. These conditions are especially preferred when a ceriumcomponent is present in the formulation in order to prevent or minimizeinteraction between cerous ions and the spinel base.

A preferred alkali metal aluminate is sodium aluminate. Although themineral acid may be nitric, hydrochloric, or sulfuric acid, tocorrespond to the selected alkaline earth metal salt, care must be takento employ water-soluble salts and, accordingly, the preferred alkalineearth metal salt is magnesium nitrate and the preferred mineral acid isnitric acid.

The concerted technique of this invention affords a precipitate phasewhich may be directly washed with water or, optionally, first permittedto age for up to about 24 hours at ambient temperature or elevatedtemperatures, prior to any further processing. Separation of theprecipitate phase may be accomplished by any conventional means, such asfiltration.

The products prepared by the process of this invention possess uniquestructures and exhibit superior properties as sulfur oxide reductionmaterials, e.g., in fluid catalyst cracking operations, when comparedwith similar products prepared by conventional methods. For example, theproducts of this invention have suitable mechanical strength and bulkdensity, better attrition rate, low deactivation rate, suitable surfacearea and pore volume, and good fluidization characteristics.

The products prepared by the process of this invention exhibit improvedSOx pickup ability and, surprisingly, different mesopore and macroporedistributions when compared to catalysts prepared in the absence of anorganic template. The process of this invention preferably proves spinelcompositions exhibiting surface areas in the range of about 25 to about600 m.² /g., more preferably about 40 m.² /g. to about 500 m.² /g. andstill more preferably about 50 m.² /g. to about 400 m.² /g.

The embodiments described below are exemplary, without limitation, ofthe process of this invention.

EXAMPLE I

The following spinel was prepared with no solid organic materialpresent.

Magnesium nitrate hexahydrate (769.2 g., 3.0 mole) was dissolved in 1500ml. water.

Sodium aluminate (Nalco) (174.6 g., 0.75 mole Al₂ O₃ and 0.85 mole Na₂O) and 119.5 g. (3.0 mole) sodium hydroxide were separately dissolved in1350 ml. water. This solution was filtered through No. 1 filter paper.

The sodium aluminate/sodium hydroxide solution was added, with stirring,to the magnesium nitrate solution over a period of 1 hour. The resultingaqueous slurry pH was monitored and was brought to a pH of 9.5 bydropwise addition of 20% NaOH solution. After stirring for an additionalhour, the slurry was permitted to age quiescently for 16 hours atambient temperature.

The slurry was filtered, washed with water to remove sodium ion, and thewashed filter cake dried at 260° F. for 16 hours in a forced air oven.The dried product was ground to pass through a 60-mesh screen. Theground product was calcined by heating gradually to 1350° F. over 4hours and being held at that temperature in a flowing air stream for anadditional 3 hours to produce a spinel-containing composition having amagnesium to aluminum atomic ratio of about 2.

EXAMPLE II

The spinel-containing composition prepared according to the procedure ofExample I, was placed in a Pyrex tray and impregnated with ceriumnitrate solution, by hand mixing using rubber gloves, to provide a levelof 10 wt. % cerium, calculated as the metal. After impregnation wascomplete, the mixture was allowed to equilibrate overnight.

The impregnated product was then dried in an oven at 260° F. for 16hours. The dried product was calcined in a fluidized state at 1350° F.for 3 hours, employing an air flow rate of about 83 liters/hour. Theresulting impregnated spinel-containing composition was screened toproduce final particles having diameters less than 100 microns.

EXAMPLE III

Hydrogenated vegetable oil (Sterotex, Stokely-VanCamp, Inc.) (60 g.) wasscreened through a 60 mesh sieve and suspended in 3900 ml. water.

Magnesium nitrate and sodium aluminate/sodium hydroxide solutions wereprepared as in Example I.

The magnesium nitrate solution was combined, with vigorous stirring,with the aqueous Sterotex suspension. The sodium aluminate/sodiumhydroxide solution was added to this combined mixture, following theprocedure of Example I.

The slurry was aged quiescently for 90 days, and then filtered, washed,dried and calcined as in Example I to produce a spinel-containingcomposition having a magnesium to aluminum atomic ratio of about 2.

EXAMPLE IV

The spinel-containing composition produced in Example III wasimpregnated with cerium, following the procedure of Example II.

EXAMPLE V

The cerium impregnated, spinel-containing compositions of the precedingExamples II and IV, after dilution to 0.75 and 1.0 wt. %, respectively,with FCC catalyst, were tested for sulfur pick-up capabilities asfollows. Each of these materials was fluidized in a gas stream,comprising (by volume) 5.9% O₂, 1.5% SO₂ and 92.6% N₂, after heating at1350° F. in a stream of nitrogen gas. After a 15-minute treatment withthe SO₂ -containing gas, the remaining SO₂ was flushed out withnitrogen. After cooling, analyses for sulfur were conducted on thesolids and on the gas stream to determine the efficiency of SOx pickupby formation of metal sulfates. The capability of these compositions topick-up sulfur is shown in Table I.

EXAMPLE VI

The diluted compositions described in Example V were steamed for 6 hoursat 1400° F. in 100% steam atmosphere, to simulate conditions in a FCCunit regenerator. These steamed compositions were again tested forsulfur pick-up as in Example V. The results of these tests are shown inTable I.

EXAMPLE VII

The sulfur-containing compositions from Examples V and VI were heated to1350° F. in flowing nitrogen gas and then for 5 minutes in a stream ofhydrogen. Each composition was flushed with nitrogen, and, aftercooling, was analyzed for sulfur content, to determine the efficiency ofsulfur removal by reduction of metal sulfates. Each of thesecompositions has a substantial capability to release sulfur under theconditions of the above-noted treatment.

                  TABLE I.sup.1                                                   ______________________________________                                        Composition     SOx                                                           of Example      Pickup, % Activity.sup.4                                      ______________________________________                                        II (Virgin).sup.2                                                                             23        24                                                  IV (Virgin).sup.3                                                                             71        63                                                  II (Steamed).sup.2                                                                            24        29                                                  IV (Steamed).sup.3                                                                            65        59                                                  ______________________________________                                         .sup.1 The FCC catalyst employed had a miner SOx pickup activity which wa     taken into account in the SOx pickup data shown below. Thus, these data       reflect the actual SOx pickup of the mixture of FCC catalyst plus             composition of Example.                                                       .sup.2 As blend of 0.75 wt. % composition of Example in FCC catalyst.         .sup.3 As blend of 1.0 wt. % composition of Example in FCC catalyst.          ##STR1##                                                                 

The test data presented in Table I show that SOx pickup is consistentlygood with spinels prepared according to the process of this invention.The spinels prepared according to this invention are (remain) effectivethrough a number of SOx pickup-release, i.e., have good activitystability.

While this invention has been described with respect to various specificexamples and embodiments, it is to be understood that the invention isnot limited thereto and that it can be variously practiced within thescope of the following claims:

The embodiments of this invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A process for the production of an alkaline earth metal, aluminum-containing spinel composition comprising:(a) combining (i) an acidic aqueous medium containing at least one alkaline earth metal component; (ii) at least one solid organic material capable of being at least partially combusted during step (b) hereof; and (iii) a basic aqueous medium containing at least one aluminum component in which the aluminum is present as an anion to form a combined mass including a liquid phase and an alkaline earth metal, aluminum-containing precipitate, provided that the pH of said combined mass during said combining is maintained at about 8.0 or higher; and (b) calcining said precipitate to form said alkaline earth metal, aluminum-containing spinel composition.
 2. The process of claim 1 wherein the pH of said combined mass during said combining is maintained in the range of about 8.0 to about 10.5.
 3. The process of claim 1 wherein the pH of said combined mass during said combining is maintained in the range of about 8.5 to about
 10. 4. The process of claim 1 wherein the pH of said combined mass during said combining is maintained in the range of about 9.0 to about 9.5.
 5. The process of claim 1 wherein said solid organic material acts to alter at least one property of said spinel composition.
 6. The process of claim 1 wherein the solid organic material is selected from the group consisting of substantially hydrocarbon materials, substantially carbohydrate materials, substantially carbonaceous materials and mixtures thereof.
 7. The process of claim 1 wherein at least a major amount of said solid organic material is capable of being combusted during said step (b).
 8. The process of claim 1 wherein said solid organic material is selected from the group consisting of hydrogenated vegetable oils, fatty acids, fatty esters, fatty ethers, natural gums, starch, starch derivatives, lignin, lignin derivatives, cellulose, cellulose derivatives, stereo-specific organic polymers, regio-specific organic polymers and mixtures thereof.
 9. The process of claim 1 wherein the solid organic material is a hydrogenated vegetable oil.
 10. The process of claim 1 wherein the atomic ratio of alkaline earth metal to aluminum in said spinel composition is at least about 0.17.
 11. The process of claim 1 wherein the atomic ratio of alkaline earth metal to aluminum in said spinel composition is in the range of about 0.17 to about 2.5.
 12. The process of claim 1 wherein the atomic ratio of alkaline earth metal to aluminum in said spinel composition is in the range of about 0.5 to about 1.5.
 13. The process of claim 1 wherein said alkaline earth metal is magnesium.
 14. The process of claim 1 wherein said calcining takes place at a temperature in the range of about 1000° F. to about 1800° F.
 15. The process of claim 1 wherein said calcining takes place at a temperature in the range of about 1050° F. to about 1600° F.
 16. The process of claim 1 wherein said calcining takes place at a temperature in the range of about 1100° F. to about 1400° F.
 17. The process of claim 1 wherein said precipitate is dried to remove at least a portion of said liquid phase prior to being calcined.
 18. The process of claim 17 wherein said precipitate is dried at a temperature of less than about 500° F.
 19. The process of claim 17 wherein said additional metal component is selected from the group consisting of Group IB metals, Group IIB metals, Group IVB metals, Group VIA and B metals, Group VIIA metals, Group VIII metals, the rare earth metals, vanadium, tin, antimony and mixtures thereof.
 20. The process of claim 19 wherein said spinel composition includes up to about 25% by weight, calculated as elemental metal, of at least one of said additional metal components.
 21. The process of claim 17 wherein said precipitate is spray dried and said spinel composition is in the form of particles having diameters in the range of about 10 to about 250 microns.
 22. The process of claim 17 wherein said precipitate is spray dried and said spinel composition is in the form of particles having diameters in the range of about 20 to about 125 microns.
 23. The process of claim 17 wherein said precipitate is maintained in contact with at least a portion of said liquid phase for a period of about 4 to about 24 hours before being dried.
 24. The process of claim 1 wherein said spinel composition includes a minor amount of at least one additional metal component effective to promote the oxidation of SO₂ to SO₃ at SO₂ oxidation conditions.
 25. The process of claim 24 wherein said additional metal component is selected from the group consisting of bismuth, rare earth metal, chromium, copper, iron, manganese, vanadium, tin, the platinum group metals, thorium and mixtures thereof.
 26. The process of claim 25 wherein said additional metal component is cerium.
 27. The process of claim 24 wherein said additional metal component is a rare earth metal.
 28. The process of claim 24 wherein said spinel composition includes up to about 25% by weight, calculated as elemental metal, of at least one of said additional metal components.
 29. The process of claim 1 wherein said aluminum component is alkali metal aluminate.
 30. The process of claim 1 wherein the weight ratio of said solid organic material to said alkaline earth metal in said combined mass is in the range of about 0.1 to about
 35. 31. The process of claim 1 wherein the weight ratio of said solid organic material to said alkaline earth metal in said combined mass is in the range of about 0.3 to about
 20. 32. In a process for reducing the sulfur oxide content of a sulfur oxide-containing gas which includes contacting said gas with a material at conditions to associate at least a portion of said sulfur oxide contained in said gas with said material, the improvement comprising utilizing as said material an alkaline earth metal, aluminum-containing spinel composition produced in accordance with the process of claim
 1. 33. In a process for reducing the sulfur oxide content of a sulfur oxide-containing gas which includes contacting said gas with a material at conditions to associate at least a portion of said sulfur oxide contained in said gas with said material, the improvement comprising utilizing as said material an alkaline earth metal, aluminum-containing spinel composition produced in accordance with the process of claim
 2. 34. In a process for reducing the sulfur oxide content of a sulfur oxide-containing gas which includes contacting said gas with a material at conditions to associate at least a portion of said sulfur oxide contained in said gas with said material, the improvement comprising utilizing as said material an alkaline earth metal, aluminum-containing spinel composition produced in accordance with the process of claim
 3. 35. In a process for reducing the sulfur oxide content of a sulfur oxide-containing gas which includes contacting said gas with a material at conditions to associate at least a portion of said sulfur oxide contained in said gas with said material, the improvement comprising utilizing as said material an alkaline earth metal, aluminum-containing spinel composition produced in accordance with the process of claim
 4. 36. In a process for reducing the sulfur oxide content of a sulfur oxide-containing gas which includes contacting said gas with a material at conditions to associate at least a portion of said sulfur oxide contained in said gas with said material, the improvement comprising utilizing as said material an alkaline earth metal, aluminum-containing spinel composition produced in accordance with the process of claim
 6. 37. In a process for reducing the sulfur oxide content of a sulfur oxide-containing gas which includes contacting said gas with a material at conditions to associate at least a portion of said sulfur oxide contained in said gas with said material, the improvement comprising utilizing as said material an alkaline earth metal, aluminum-containing spinel composition produced in accordance with the process of claim
 19. 38. In a process for reducing the sulfur oxide content of a sulfur oxide-containing gas which includes contacting said gas with a material at conditions to associate at least a portion of said sulfur oxide contained in said gas with said material, the improvement comprising utilizing as said material an alkaline earth metal, aluminum-containing spinel composition produced in accordance with the process of claim
 30. 39. In a process for reducing the sulfur oxide content of a sulfur oxide-containing gas which includes contacting said gas with a material at conditions to associate at least a portion of said sulfur oxide contained in said gas with said material, the improvement comprising utilizing as said material an alkaline earth metal, aluminum-containing spinel composition produced in accordance with the process of claim
 31. 